Development and Implementation of 2G SAW on C3 Splitter

Sanket Singh Welding Technology ISGEC Hitachi Zosen Ltd

Topics covered
Development & Implementation Purpose Design of WEP Welding Operator Training and Qualification Set-Up Welding Parameters PQR Establishment On job execution Comparison of SMAW with SAW in Horizontal position & Radiographic quality Process Limitations Conclusion
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Development & Implementation Purpose:

ISGEC HITACHI ZOSEN LTD Job DV-204 (C3 Splitter)
Total Height: 95.7 Meters Fabricated weight = 660 Tons Total weld metal deposition required = 8000 Kg Total weld metal deposited by SMAW per arc hour = 1.5 Kg (Approx) Total weld metal deposited by 2G SAW per arc hour = 6.0 Kg (Approx) To meet on time delivery schedule with quality Resource constraints e.g. Rotator, Cranes

Design of WEP
Full accessibility of 2G SAW nozzle tip Ease of bead sequencing Adjustment of welding parameters without affecting weld soundness

Welding Operator Training and Qualification

As the process demands dedicated manpower skill, rigorous training and qualification is required to improve knowledge and skill of welding operator and supervisors for monitoring the welding involved.

Main areas for training

Set Up and Machine Details Welding Parameters and process principles.

Set Up
As welding is to be carried out in horizontal position below given points are must requirement There should be proper access for 2G SAW nozzle within groove. Arrangement for holding and collecting flux. Proper arrangement for resting control panel. Arrangement for movement of 2G SAW head Arrangement for manipulation of SAW 2G nozzle within groove. (Both To and Fro, Up and down movement) Welding operator comfortness

2G SAW SET-UP
Channel: For movement of SAW frame Frame with rolls : For movement in horizontal position Wire Spool Holder with adjustment clamp

Nozzle, Frame, Flux Pipe, Travel Guide, Flux belt

Flux Pipe

Nozzle Tip with nozzle holder

Welding Direction Travel Guide Flux Belt with Roller support Frames

Roller, Guide & Motor

Mechanism for tightening the stationary rolls

Stationary Rollers Drive Rollers

Motor

Horizontal, Vertical and Angular movement control knob

Angular movement control knob

Fixed clamp for vertical motion

Horizontal movement knob

Control Panel (Ammeter, Voltmeter, speed indicator)

Speed control

Wire Feed control (Current control)

Welding Parameters
Welding parameters for 2G SAW process are more or less similar for Root and fill up pass as it is for Flat position SAW, while the parameters for capping pass is different (speed). Refer below Table 1 for welding parameters.

Pass Root Pass Fill Up Pass Covering Pass

Current 450-550 450-550 450-550

Voltage 28-32 28-32 28-32

Speed 450-550 450-550 600-700

PQR Establishment
Purpose for establishing a PQR Check whether the parameter settings and arrangements are desirable for producing a sound weld metal with minimum problems. To establish a sequence for bead placement. To check weld metal properties after completion of welding to determine the effectiveness of parameters w.r.t to Base metal properties. To establish machine settings for subsequent operation. Execution of PQR and weld metal Properties: Base material: SA516Gr70 Thickness: 56mm Consumable: EH10K + Supershield C4 (Super alloys and Metals) Parameters: Refer Table 1 Preheating: 75 0C Interpass: 275 0C Properties: After 8 Hr of heat treatment at 610-611 0C Tensile strength: 485 Mpa ( Failure in Base metal) Hardness: 198 BHN (Max in weld) Impact: 160 J (Min in weld), 101 J (Min in HAZ) at -29 0C Macro: Satisfactory
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Execution of PQR

Picture 1: Execution of PQR

Picture 2: Bead Placement

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On Job Execution: 2G SAW was implemented on more than 24 Circular seams (ISGEC Job DV204), carrying out 4800 KG of weld deposition . Total time involved for completion of welding was 72 days. 2G SAW was applied on following areas 1) Circular seam (Cylindrical shell # Cylindrical shell, refer Picture 3) 2) Circular seam (Conical skirt shell # Conical skirt shell, refer Picture 4) 3) Circular seam ( Cylindrical shell # Ellipsoidal Dished end, refer Picture 5) 4) Fillet Joint (Conical Skirt # Compression ring, refer Picture 6) 5) Skirt to Dished end welding (Refer Picture 7 )

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On job Execution

Picture 3: Circular seam (Cylindrical shell # Cylindrical shell)

Picture 4: Circular seam (Conical skirt shell # Conical skirt shell)

Picture 5: Circular seam ( Cylindrical shell # Ellipsoidal Dished end)

Picture 6: Fillet Joint (Conical Skirt # Compression ring)

Picture 7: Dished end to Skirt joint

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Picture 8: Weld Aesthetics & Bead placement

Comparison of SMAW with SAW in Horizontal position

Process Production

SMAW 1.5 Kg per arc Hr (Approx) 3200 Arc Hr

SAW 2G 6 Kg per arc Hr (Approx) 800 Arc Hr

Total weld metal=4800KG

Saving of arc Hr = 2400 arc Hr by SAW 2G Radiographic Test Result: Total rejection found 360mm in 360000mm of weld length i.e. 0.1%

Process Limitations
1) Requires WEP w.r.t application. 2) Requires skilled manpower to operate independently; semi skilled man power under frequent observation. 3) Required special Tools and Tackles. 4) Rigorous training shall be imparted to welding operator for bead placement.

Conclusion:
It is quite apparent from the development process that 2G SAW is very productive process, it is minimum four times faster than SMAW on production scale, the aesthetic look of welds is also very good, the process has produced good results in Radiographic Testing. (Total rejection found 360 mm in length of 360000 mm i.e. 0.1 % )